High definition door skin and method of manufacturing the same

ABSTRACT

A cushion assembly for forming metallic door skins in an industrial press, the method of manufacturing a door skin using the cushion assembly and the door skin produced by that method. The cushion assembly has a plurality of gas-filled cylinders positioned around the perimeter of said cushion assembly, a solid interior disposed within said perimeter of said gas-filled cylinders and a transfer pad disposed on top of said gas-filled cylinders. In some aspects, the solid interior comprises a plurality of solid cylinders or blocks wherein the solid cylinders extend through openings in the transfer pad and the openings are sized and shaped to be complementary with said solids cylinders or blocks.

FIELD OF THE INVENTION

The invention relates generally to the manufacturing of door skins, and more particularly, to high definition door skins and to an apparatus and method for manufacturing such door skins.

BACKGROUND OF THE INVENTION

Contemporary metallic doors are constructed of thin metallic door skins that comprise the exterior of the door. Door skins are formed from hot dipped galvanized deep drawing steel that is stamped into the desired door shape. The door skins form the exterior of the door and can be joined at the perimeter of the skins on flanges, or the door skins can be joined to a frame between the skins. A foam core can be used to fill the internal cavity left between the door skins.

The appearance of metallic doors lagged behind that of wooden doors for many years until the introduction of embossments that increased the aesthetic appearance of metallic doors by allowing the introduction of geometric impressions into the door skin. By stamping metallic door skins between male and female dies in a conventional press, door manufacturers were able to produce metallic doors that rivaled the appearance of carved wooden doors. However, wood doors provided geometric carvings that were not capable with conventional embossing techniques for metallic doors. Moreover, the edges of the embossments in metallic doors were not defined and the number of consecutive parallel edges or radii in metallic door embossments could not match carvings in wooden doors. Even fiberglass doors that were introduced into the market soon after metallic doors, had more definition in the door designs and geometric impressions. The number of radii in a design was limited, which greatly reduced the creativity and the number of possible designs that could be embossed into metallic doors. The depth of embossments in metallic door skins and the profile of the door skins were limited as well. Attempts at more intricate and defined embossments in metallic door skins using conventional pressing techniques led to overstress, warping and damage to the steel blank. Steel doors had the advantages of durability, reduced cost of manufacture, insulation efficiency, etc., but the inability to match the definition of wooden and fiberglass door designs was an unsolved problem.

Furthermore, conventional door skin stamping methods and machinery using conventional presses and cushion assemblies have drawbacks. Conventional cushion assemblies used with typical door skin presses have a high failure rate for the gas-filled cylinders in the cushion assemblies, which increases manufacturing time and costs.

Thus, there is a long-felt need to provide a metallic door skin with an increased number of radii and complexity in embossments that rival wooden and fiberglass doors. There is a further need for an apparatus and method of manufacturing a metallic door skin that reduces cushion failure rate, increases the number of radii in a metallic door skin design, increases the profile range of a metallic door skin, and the range of possible embossment depths.

SUMMARY OF THE INVENTION

The invention broadly comprises a cushion assembly for forming metallic door skins in an industrial press, such as, but not exclusive to hydraulic, mechanical, or pneumatic presses. Also, the method of manufacturing a door skin using the cushion assembly and the door skin produced by that method. The cushion assembly has a plurality of gas-filled cylinders positioned around the perimeter of said cushion assembly, a solid interior disposed within said perimeter of said gas-filled cylinders and a transfer pad disposed on top of said gas-filled cylinders.

In some aspects, the solid interior comprises a plurality of solid blocks and the solid blocks extend through openings in the transfer pad. In some aspects, the solid interior comprises at least one solid block and the solid block extends through an opening in the transfer pad.

In some aspects, the gas-filled cylinders have a chamber that retains pressurized gas and the pressure of each gas-filled cylinder can be regulated. The gas used in the gas-filled cylinders can be nitrogen gas, although other alternatives are possible.

In some aspects, the plurality of gas-filled cylinders are detachably connected to a manifold system and the manifold system is connected to a gas bank, using nitrogen gas or a similar alternative, that uniformly regulates gas pressure in the gas-filled cylinders.

The invention also broadly comprises, a metallic door skin formed from a blank having at least one embossment that is at least 1.755 inches wide and the embossment has at least 4 radii across the embossment. In some aspects, the embossment has a depth less than 0.312 inches. The embossment can have a width range from 1.76 to 3.29 inches with between 4 and 6 radii. In some aspects, the embossment has a depth range from 0.313 to 0.10 inches.

The invention also broadly comprises, a method of manufacturing a metallic door skin, with the steps of inserting a steel blank between a male die and a female die; pressing the steel blank between the male die and the female die in a die set upon a cushion assembly with an industrial press, such as an industrial press, which can include a hydraulic, mechanical, or pneumatic press; supporting the die set with the cushion assembly having a solid member disposed in an interior of the cushion assembly; supporting a force exerted by the press around a perimeter of the cushion assembly with a plurality of absorbent cushions, where a perimeter of the steel blank is compressed between the die sets and the absorbent cushions of the cushion assembly; and, punching at least one embossment in the steel blank to produce a door skin.

In some aspects, the method includes the step of regulating the pressure in the plurality of cushions, where the pressure can be regulated uniformly by a manifold.

In some aspects, the embossment is at least 1.755 inches wide, has at least 4 radii across the embossment, and has a depth that is less than 0.312 inches.

It is a general object of the present invention to provide a metallic door skin and a method of manufacturing the same that increases the definition of the embossments in the door skin.

It is another object of the present invention to provide a metallic door skin and a method of manufacturing the same that increases the number of radii per design.

It is another object of the present invention to provide a metallic door skin and a method of manufacturing the same that increases the range of profiles possible for a metallic door skin.

It is another object of the present invention to provide a metallic door skin and a method of manufacturing the same that increases the range of embossment depths possible for a metallic door skin.

These and other objects and advantages of the present invention will be readily appreciable from the following description of preferred embodiments of the invention and from the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a press with a cushion assembly of the present invention;

FIG. 2 is an exploded perspective view of a cushion assembly of the present invention;

FIG. 3 is plan view of a manifold of a cushion assembly with a transfer pad positioned on top of cushion cylinders;

FIG. 4 is a cross-sectional view of a manifold of the cushion assembly shown in FIG. 3, taken generally along line 4-4 in FIG. 3;

FIG. 5 is plan view of a manifold of a cushion assembly with a transfer pad positioned on top of cushion cylinders;

FIG. 6 is a cross-sectional view of the cushion assembly in FIG. 5, taken generally along line 6-6 in FIG. 5;

FIG. 7 is a front elevational view of a press and cushion assembly with die sets in the stamping position;

FIG. 8 is a top plan view of a door skin; and,

FIG. 9 is a cross-sectional view of an embossment of the door skin in FIG. 8, taken generally along line 9-9 in FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the invention. While the present invention is described with respect to what is presently considered to be the preferred aspects, it is to be understood that the invention as claimed is not limited to the disclosed aspects. In the description below, the terms “top”, “bottom”, “upper”, “lower”, “front”, “back”, “rear”, “left”, “right”, and their derivatives, should be interpreted from the perspective of one viewing the press shown in FIG. 1, or the door skin in FIG. 8.

Furthermore, it is understood that this invention is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices, and materials are now described.

FIG. 1 is a perspective view of press 8 with cushion assembly 12 of the present invention. Press 8 is an industrial press, which can include, but is not limited to a mechanical, pneumatic and/or hydraulic presses, used to stamp sheet steel into various forms. Press 8 has an upper member 9 and base member 11 that cushion assembly 12 is disposed upon. As press 8 is activated upper member 9 is driven down toward base member 10 on pistons 11. In some aspects, press 8 exerts a force of 1500 tons to stamp embossments in sheet steel to form metallic door skins, but it should be appreciated that different forces can be used to exert the necessary force to form the embossments and that various presses known to one or ordinary skill in the art can be utilized.

Cushion assembly 12 is used in conjunction with press 8 to form the aforementioned door skins. Cushion assembly 12 has manifold 14 with multiple cushions 16 detachably connected. Cushions 16 are gas-filled cylinders that have an outer housing with a piston centered within the housing. Cushions 16 have an inert gas, such as nitrogen, injected into a chamber in the cylinder to effect pressure in the cushions. Pressure adjustments in cushions 16 affect the resiliency and support the cushions provide.

Resting atop cushions 16 is transfer pad 18 with solid block 20, formed separately from transfer pad 18, but disposed in opening 22 in transfer pad 18. Solid block 20 and opening 22 are depicted in this particular figure to be rectangular shaped, but various other shaped and sized sections could also be implemented some of which will be described in greater detail infra. Conventional cushion assemblies have cushion cylinders distributed across the surface of the manifold, as opposed to cushion assembly 12 which an interior that is empty except for block 20. This reduction in the number of cushion cylinders reduces the failure rate just by reducing the number of cushions required. The failure rate of cushions 16 is also reduced by replacing the section of cushion assembly 12 that absorbs the impact of the die set stamping, namely the interior, with solid block 20.

Manifold 14 distributes pressurized gas to cushions 16 that can be detachably connected to the manifold. Ports 24 in the side of manifold 14 can provide access to the interior recesses of manifold 14, and can enable gas bank 26, or another gas dispensing unit, to pressurize and regulate the pressure in cushions 16. Gas bank 26 holds pressurized gas that is fed through line 28 to feed port 23 in manifold 14, and pressure valve 29 and gauge 25 is implemented as a means to regulate and monitor gas pressure. In some aspects, gas bank 26 provides the gas pressure throughout manifold 14 and the individual cushion cylinders 16, as manifold 14 connects cylinders 16 on a circuit. In some aspects, the gas contained in gas bank 26, and distributed through manifold 14 and cushions 16 is nitrogen gas. Other gases used in pressurized systems, such as cushion cylinders 16, that are known in the art can be substituted for nitrogen gas. Consequently, the gas that pressurizes manifold 14 and cushions 16 is not limited to only nitrogen.

In some aspects, cushions 16 are detachably connected to manifold 14, and all cushions 16 are in a pressurized circuit. Therefore, increasing or decreasing the pressure in manifold 14 increases or decreases the pressure in all the cushions connected to manifold 14. In other aspects, it may be beneficial to regulate and adjust pressure in cushions individually (not shown). To accomplish this adjustment, pressure is regulated by pressure valves that are dedicated to single cushions, which can be manually controlled or regulated and adjusted by an automated process controlled by an electronic system. Providing adjustability to individual cushions enables the operator of the press to control the amount of support transfer pad 18 provides at different regions of the manifold to adapt to different die sets or embossments intended. Certain die sets may require additional support only at a portion of the perimeter of the manifold, and regulating pressures in cushions on an individual basis enables the cushion assembly to adapt to those parameters. Cushions 16 can be commonly used gas-charged shock absorption units of varying dimension and pressure ranges. Gas springs or cushions that are capable of varying pressures exerted by the devices are preferred since they enable the press to be adapted to different applications and production requirements.

It should be appreciated that cushions 16 can be detachably connected to manifold 14 using various detachable connection means, and that illustrations showing threaded connections are only one possible alternative. Any of the various detachable connection means known in the art can be implemented. Furthermore, in some aspects, cushions 16 can be connected to manifold 14 using a connection that is not detachable.

FIG. 2 is an exploded perspective view of cushion assembly 12 of the present invention exhibiting a cushion pattern where the interior of manifold 14 has no cushions 16 connected. Interior portion of manifold 14 instead has solid block 20 surrounded by cushions 16 around the perimeter of manifold 14. Transfer pad 18 rests atop cushions 16 and solid block 20. Block 20 is positioned in opening 22. Vertical lines starting at the corners of die set 32 and ending at roller assemblies 30 indicate the general alignment of die set 32 when fully pressed. In some aspects, cushion assembly 12 eliminates roller assemblies 30 and have die set 32 resting proximate the position of roller assemblies 30. Vertical lines starting at the corners of transfer pad 18, and ending at the inside edge of roller assemblies 30, indicate the general alignment of transfer pad 18 on top of cushions 16.

In some aspects, solid block 20 is a height sufficient to have the top of block 20 to remain generally flush with the top of transfer pad 18 when cushion assembly 12 is fully assembled. The fit of block 20 is also complementary to opening 22 in that the parameters of block 20 is roughly equivalent to the parameters of opening 22. As die set 32 is pressed downward against cushion assembly 12, solid block 20 provides support for female die 34 and male die 36 to emboss sheet steel blanks that are placed between female die 34 and male die 36. Cushions 16 provide pressurized resistance around the perimeter of cushion assembly 12 that distributes force exerted by press 8 to the perimeter, which enables cushion assembly 12 and die set 32 to compress and grip the perimeter of sheet steel blanks that are pressed. In some aspects, block 20 is positioned to provide support at regions where die set 32 will emboss a blank. Specifically, embossments may only be pressed into the blank at regions where solid support has been provided. As die set 32 is pressed against transfer pad 18 and solid block 20, cushions 16, arranged around the perimeter of manifold 14, force transfer pad 18 to bind the perimeter of sheet steel blanks inserted into die set 32 to prevent slipping of the blank during stamping. This compression or gripping of the blank at the perimeter, which is caused by the perimeter cushions 16 exerting resistance against transfer pad 18, facilitates that the blank is not warped or deformed to any undesirable extent when die set 32 punches out the embossment in the blank. Solid block 20 ensures that die set 32, which has higher definition dies, can effectively punch out the higher definition embossments in the blank. Higher definition refers to a higher number of radii distributed possible across an embossment, the depth and profile ranges of the door skin embossments is broader and/or the embossments are more defined with shadowing that gives a more pronounced appearance. In some aspects, transfer pins (not shown) that are solid steel structures that extend from the base of the perimeter of die set 32 can be used to exert force on transfer pad 18 as press 8 stamps a steel blank. The transfer pins are best positioned on the bottom and at the perimeter of the die set and can ensure that the edge of blank is securely held to prevent warping as the die set stamps the embossment in the blank.

FIG. 3 is plan view of manifold 14 of cushion assembly 12 showing the interior portion of manifold 14 devoid of cushions 16. Transfer pad 18 is shown positioned on top of cushions 16. A portion of the interior of cushion assembly 12 has been replaced by solid block 20, while the perimeter of manifold 14 has multiple cushions 16 connected. Cushions 16 are shown in dashed lines to indicate the position of cylinders 16 under transfer pad 18, and to indicate that transfer pad 18 is positioned over cushion cylinders 16. Although FIG. 3 shows cushions 16 arranged in a particular order, this arrangement is only one variation on the distribution of cushions 16 in cushion assembly 12. However, it should be noted that the void of cushions 16 in the interior portion of cushion assembly 12 enables cushion assembly 12 to properly distribute force to ensure that press 8 can produce door skins of the present invention.

FIG. 4 is a cross-sectional view of manifold 14 of cushion assembly 12 shown in FIG. 3, taken generally along line 4-4 in FIG. 3. Cushions 16 are shown attached to manifold 14 with threads 17. However, the connection of cushions 16 to manifold 14 is not limited to this attachment means. Furthermore, attachment of cushions 16 can be accomplished by a non-detachable connection means. Positioned under cushion cylinders 16 is channel 17 that is used to introduce pressurized gas into the cushion. Channels 17 run the length of manifold 14 and connect cushions 16 in a circuit, which enables gas pressure in each cushion to be regulated together. In alternative embodiments, each cushion can have a separate channel and the cushions are controlled individually as opposed to being linked in a circuit.

Solid block 20 is shown attached to manifold 14 with threaded attachment means. In some embodiments, solid block 20 can have a threaded base that threads into threaded bolts in manifold 14, or can be detachably connected in another manner known in the art. In some aspects, solid block 20 is fixedly attached to manifold 14. Solid block 20 has a height that is roughly the combined height of cylinders 16 and transfer pad 18, and block 20 has a width and length that is roughly equivalent to the width and length of opening 22.

FIG. 5 is a plan view of alternative cushion assembly 112 with cushions 116 attached to manifold 114 with transfer pad 118 positioned on top of cushions 116. Cushion assembly 112 is used with a press similar to press 8, and acts as the support for die set 32, as die set 32 is pressed against cushion assembly 112 during the stamping process. Cushions 116 are shown in dashed lines to indicate the presence of transfer pad 118 on top of the cushions. Similar to the arrangement of cushions 16 in cushion assembly 12, cushions 116 are arranged around the perimeter of manifold 114. Cushions 116 can be commonly used gas-charged shock absorption units of varying dimension and pressure ranges. Gas springs or cushions that are capable of varying pressures exerted by the devices are preferred since they enable the press to be adapted to different applications and production requirements.

Solid block 20 has been replaced by multiple solid blocks 120 in the interior of manifold 14. Multiple solid blocks 120 function similarly to the solid block 20 in that solid blocks 120 support male die 36 and female die 34 to enable the stamping of previously unattainable embossment designs. Blocks 120 and openings 122 are depicted as a rectangular, but other possible alternative shapes can be used depending on the die set chosen or the press used, or other reasons. As die set 32 is pressed against transfer pad 118 and solid blocks 120, cushions 116 arranged around the perimeter of manifold 114 force transfer pad 118 to bind the perimeter of sheet steel blanks inserted into die set 32 to prevent slipping of the blank during stamping. This compression or gripping of the blank at the perimeter, which is caused by the perimeter cushions 116 exerting resistance against the transfer pad, facilitates that the blank is not warped or deformed to any undesirable extent when the die set punches out the embossment in the blank. Solid blocks 120 ensure that die set 32, which has higher definition dies, can effectively punch out the higher definition embossments in the blank. In some aspects, transfer pins (not shown) that are solid steel structures that extend from the base of the perimeter of die set 32 can be used to exert force on transfer pad 118 as the press 8 stamps a steel blank. The transfer pins are best positioned on the bottom at the perimeter of the die set and can ensure that the edge of blank is securely held to prevent warping as the die set stamps the embossment in the blank.

A cross-sectional view of cushion assembly 112 taken generally along line 6-6 in FIG. 5 is shown in FIG. 6. In this view the height and position of solid blocks 120 is evident in relation to transfer pad 118 and cushions 116. Transfer pad 118 rests atop cushions 116 with blocks 120 positioned within openings 122 of the transfer pad. Cushions 116 are shown attached to manifold 114 with threads 117. However, the connection of cushions 116 to manifold 114 is not limited to this attachment means. Furthermore, attachment of cushions 116 can be accomplished by a non-detachable connection means. Positioned under cushion cylinders 116 is channel 127 that can be used to introduce pressurized gas into the cushion. Channels 127 run the length of manifold 114 and join all cushions 116 in a circuit. In alternative embodiments, each cushion can have a separate channel and the cushions are controlled individually as opposed to being linked in a circuit.

Solid blocks 120 are shown attached to manifold 114 with threaded attachment means. In some embodiments, solid blocks 120 can have a threaded base that can be attached with a threaded attachment means to manifold 114, or can be detachably connected in another manner known in the art. In some aspects, solid blocks 120 are fixedly attached to manifold 114. Solid blocks 120 have a height that is roughly the combined height of cylinders 116 and transfer pad 118, and blocks 120 has a length and width that is roughly equivalent to the length and width of openings 122. Openings 122 are shaped and sized to be complementary with blocks 120. Any vertical displacement of transfer pad 118 will have solid blocks 120 riding within openings 122.

The interior of manifold 114 has multiple solid blocks 120 arranged to support die set 32 as press 8 compresses a blank that has been inserted between female die 34 and male die 36. The perimeter arrangement of cushions 116 supports transfer pad 118, with cushions 116 providing the resistance that enables the transfer pad to compress the perimeter of a sheet steel blank to prevent movement or suck of the blank edge during stamping. Solid blocks 120 provide the support for die set 32 as the press stamps a blank. Perimeter binding of the blank edge, due to cushions 116 around the perimeter, combined with the contrasting non-cushioned center of manifold 114, due to solid blocks 120, produces a door skin with embossments that are more refined with higher definition. The perimeter edge of the door skin produced by press 8 using cushion assembly 112 can reduce or eliminate warping, due to the perimeter cushioning and solid center of manifold 114. As die set 32 is pressed against transfer pad 118 and solid blocks 120, cushions 116 arranged around the perimeter of manifold 114 force the transfer pad to bind the perimeter of sheet steel blanks inserted into die set 32 to prevent slipping of the blank during stamping. This compression or gripping of the blank at the perimeter, which is caused by the perimeter cushions 116 exerting resistance against the transfer pad, facilitates that the blank is not warped or deformed to any undesirable extent when the die set punches out the embossment in the blank. Solid blocks 120 ensure that die set 32, which has higher definition dies, can effectively punch out higher definition embossments in the blank.

FIG. 7 is a front elevation view of press 8 shown in FIG. 1 with die set 32 in the stamping position. Reference to a “stamping position” is to signify that upper press assembly 9 has been lowered toward press base 10 into position to stamp embossments into sheet steel blank 38. Sheet steel blank 38 is fed through die set 32. As blank 38 is fed through die set 32 it is inserted between female die 34 and male die 36, which form die set 32. Pressure exerted by press 8 upon die set 32 forces the die set toward transfer pad 18 and solid block 20. As the bottom of die set 32 approaches transfer pad 18 and solid block 20, cushion cylinders 16 exert a force against transfer pad 18 that compresses the perimeter of blank 38 to prevent blank 38 from sucking inward at the perimeter of the blank during the stamping of embossments in blank 38 with die set 32. The force from die set 32 can also be transferred to transfer pad 18 with transfer pins (not shown) as described supra.

Due to the force exerted by cushions 16 against the bottom of transfer pad 18, and the solid block 20 in the interior of cushion assembly 12, die sets that punch higher definition embossments are possible without warping or stressing blanks 38. Solid block 20 in cushion assembly 12 provides the rigid support needed to produce higher definition embossments that have greater detail, increased radii, and profiles with broader depth and width ranges. Cushions 16, lining the perimeter of the cushion assembly, provide the gripping force needed to prevent blank 38 from slipping, warping, or deforming during this intense pressing process. Similar support is provided by solid block 20 and solid blocks 120, and cushions 116 function similarly to cushions 16. The stamping process described is applicable and functions similarly with cushion assemblies 12 and 112.

FIG. 8 is a top plan view of door skin 300 having upper rectangular embossment 302 and lower rectangular embossment 304. The embossments shown are not a closed set of possible embossments designs capable with the disclosed method and apparatus. Numerous other design shapes are possible using cushion assemblies 12 and 112, high definition die sets and the method implementing those elements. In some aspects, door skins 300 are manufactured from sheet steel. However, it should be understood that any material known in the art can be used to manufacture door skins 300. Door skin 300 is manufactured using press 8 used with cushion assembly 12 and 112 described supra. In particular, previously described cushion assemblies 12 and 112 provide the contrasting degree of support from perimeter cushions 16 and 116, which interact with transfer pads 18 and 118, respectively, to prevent the blank stamped by die set 32 from slipping during the stamping process. Solid inserts 20 and 120 provide the resiliency needed during the stamping process for die set 32 to press more complex door skins. High definition die set 32 stamp a pattern in a sheet steel blank that was previously not achievable with conventional door skin stamping cushion assemblies. Conventional cushion assemblies have cushion cylinders distributed across the manifold surface. Therefore, the cushion assemblies disclosed herein provide non-absorbent solid support in the center or interior of the cushion assembly matched with an absorbent cushion lined perimeter, which traditional cushion assemblies can not provide.

An increased number of radii produced by die set 32 are possible due to the characteristics of cushion assemblies 12 and 212 and the disclosed method. In some aspects, radii 306, 308, 310 and 312 can be stamped into a sheet steel blank using the process and apparatus described supra. Alternative embossment designs, with more than four radii, can also be stamped into steel blanks with different die sets, due to cushion assemblies 12 and 112. Cushion assemblies 12 and 112, and obvious variants of those cushion assemblies can accommodate higher definition die sets that previous cushion assemblies were not capable of handling. Pressing more complex die sets with more than three radii using traditional cushion assemblies would cause tearing, warping, and/or strain on steel blanks.

FIG. 9 is a cross-sectional view of embossment 302 of door skin 300 in FIG. 8, taken generally along line 9-9. In some aspects, radii 306, 308, 310 and 312 are stamped into a sheet steel blank using the apparatus and process described supra. In some aspects, door skin 300 has radii 306, 308, 310 and 312 stamped across a width ranging from 1.75-3.29 inches measured from interior perimeter 314 of the embossment to exterior perimeter 316 of the embossment. In some aspects, the embossments can have widths greater than 3.29. Door skin 300 also has an embossment depth of less than 0.312 inches measure from peak 318 to trough 320 of embossment 302, with a preferred depth ranging from 0.312 inches to 0.10 inches. Embossments have greater than three radii, leading to an embossment design offering greater detail and complexity. In should be understood that changes in the embossment design are possible and that embossments of the present invention are not limited to exemplary embodiments depicted in 302 and 304. Other shapes and designs are possible that would fall within the radii, width and depth ranges described supra. The ranges in width, length and number of radii depicted in this description are all possible alternatives using the apparatus and process described supra, and other embodiments falling within these ranges are encompassed by the present invention.

Thus, it is seen that the objects of the invention are efficiently obtained, although changes and modifications to the invention should be readily apparent to those having ordinary skill in the art, without departing from the spirit or scope of the invention as claimed. Although the invention is described by reference to a specific preferred embodiment, it is clear that variations can be made without departing from the scope or spirit of the invention as claimed. 

1. A cushion assembly for forming metallic door skins in an industrial press, comprising: a plurality of gas-filled cylinders positioned around the perimeter of said cushion assembly; a solid interior disposed within said perimeter of said gas-filled cylinders; and a transfer pad disposed on top of said gas-filled cylinders.
 2. The cushion assembly of claim 1, wherein said solid interior comprises a plurality of solid blocks.
 3. The cushion assembly of claim 2, wherein said solid blocks extend through openings in said transfer pad.
 4. The cushion assembly of claim 1, wherein said solid interior comprises at least one solid block.
 5. The cushion assembly of claim 4, wherein said solid block extends through openings in said transfer pad.
 6. The cushion assembly of claim 1, wherein said gas-filled cylinders have a chamber that retains pressurized gas.
 7. The cushion assembly of claim 6, wherein said pressure of each gas-filled cylinder is regulated.
 8. The cushion assembly of claim 6, wherein said gas is nitrogen gas.
 9. The cushion assembly of claim 1, wherein said plurality of gas-filled cylinders are detachably connected to a manifold system.
 10. The cushion assembly of claim 9, wherein said manifold system is connected to a gas bank that uniformly regulates gas pressure in said gas-filled cylinders.
 11. The cushion assembly of claim 9, wherein said gas is nitrogen.
 12. A metallic door skin, comprising: a blank having at least one embossment that is at least 1.755 inches wide and said embossment having at least 4 radii across said embossment.
 13. The metallic door skin of claim 12, wherein said embossment has a depth less than 0.312 inches.
 14. The metallic door skin of claim 12, wherein said embossment has a width range from 1.76 to 3.29 inches.
 15. The metallic door skin of claim 12, wherein said embossment has between 4 and 6 radii.
 16. The metallic door skin of claim 12, wherein said embossment has a depth range from 0.313 to 0.10 inches.
 17. A method of manufacturing a metallic door skin, comprising: inserting a sheet steel blank between a male die and a female die; pressing said sheet steel blank between said male die and said female die upon a cushion assembly with an industrial press; supporting said die sets with said cushion assembly having a solid member disposed in an interior of the cushion assembly; supporting a force exerted by said press around a perimeter of said cushion assembly with a plurality of absorbent cushions; wherein a perimeter of said steel blank is compressed between said die sets and said absorbent cushions of said cushion assembly; and, punching at least one embossment in said steel blank to produce a door skin.
 18. The method of claim 17, further comprising regulating a pressure in said plurality of cushions.
 19. The method of claim 18, wherein said pressure is uniformly regulated by a manifold.
 20. The method of claim 17, wherein said embossment is at least 1.755 inches wide and said embossment has at least 4 radii across said embossment.
 21. The method of claim 20, wherein said embossment has a depth that is less than 0.312 inches. 